Semiconductor module

ABSTRACT

A semiconductor module includes a die pad frame; a semiconductor chip disposed in a chip region on an upper surface of the die pad frame, the semiconductor chip having an upper surface on which a first electrode is disposed and a lower surface on which a second electrode is disposed; a conductive connection member for die pad disposed between the second electrode of the semiconductor chip and the upper surface of the die pad frame, the conductive connection member for die pad electrically connecting the second electrode of the semiconductor chip and the upper surface of the die pad frame; and a sealing resin for sealing the semiconductor chip, the die pad frame, and the conductive connection member for die pad.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims the benefit of priority under 35 U.S.C. § 120 from U.S. application Ser. No. 16/092,908, filed on Oct. 11, 2018, which is a U.S. national stage application under 35 U.S.C. § 371 of PCT/JP2018/020473, filed on May 29, 2018, the entire contents of each of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to semiconductor modules.

BACKGROUND ART

Conventionally known semiconductor modules may include a semiconductor chip, a lead frame electrically connected to the semiconductor chip by a bonding wire, a sealing resin for sealing the semiconductor chip and the lead frame, and a die pad frame connected to the semiconductor chip by a bonding agent or the like (for example, see JP H06-260572 A and JP 2008-311366 A).

Such a semiconductor module has a protrusion at an end portion of the die pad frame to improve the adhesion between the sealing resin and the die pad frame.

The semiconductor module, however, has a problem of a crack K and a separation of the sealing resin H caused at the end portion of the die pad frame DF on which the semiconductor chip is disposed (FIGS. 14 and 15).

DISCLOSURE OF THE INVENTION Problem to be Solved by the Invention

Under the circumstance, it is an object of the present invention to provide a semiconductor module capable of preventing the flow of a conductive connection member that electrically connects a semiconductor chip and a die pad frame in a region at an end of the die pad frame, while preventing the occurrence of a crack or separation of a sealing resin at an end portion of the die pad frame.

Solution to Problem

A semiconductor module, according to an embodiment of an aspect of the present invention, comprising:

-   -   a die pad frame;     -   a semiconductor chip disposed in a chip region on an upper         surface of the die pad frame, the semiconductor chip having an         upper surface on which a first electrode is disposed and a lower         surface on which a second electrode is disposed;     -   a conductive connection member for die pad disposed between the         second electrode of the semiconductor chip and the upper surface         of the die pad frame, the conductive connection member for die         pad electrically connecting the second electrode of the         semiconductor chip and the upper surface of the die pad frame;         and     -   a sealing resin for sealing the semiconductor chip, the die pad         frame, and the conductive connection member for die pad,     -   wherein the die pad frame has a projection disposed on the upper         surface at an end portion of the die pad frame and protruding         from an upper surface of a main body of the die pad frame in a         direction that is parallel to the upper surface of the main body         of the die pad frame, the projection being intended to improve         the adhesion with the sealing resin, and     -   wherein the projection has, at its end, a locking portion that         is partially located above an upper surface of the projection.

In the semiconductor module,

-   -   further comprising:     -   a first clip frame disposed on the upper surface of the         semiconductor chip; and     -   a first clip conductive connection member disposed between the         first electrode on the semiconductor chip and a lower surface of         the first dip frame, the first dip conductive connection member         electrically connecting the first electrode of the semiconductor         chip and the lower surface of the first clip frame.

In the semiconductor module,

-   -   wherein the locking portion has a step portion that protrudes         upward from the upper surface of an end portion of the         projection.

In the semiconductor module,

-   -   wherein the locking portion has two or more step portions that         protrude upward from the upper surface of the end of the         projection.

In the semiconductor module,

-   -   wherein a height of a top part of the locking portion is higher         than a height of a top part of the conductive connection member         for die pad so as to block a flow of the conductive connection         member for die pad.

In the semiconductor module,

-   -   wherein a length of the locking portion in the direction in         which the projection extends is shorter than a length of the         projection excluding the locking portion.

In the semiconductor module,

-   -   wherein the projection is continuously disposed around a         perimeter of an end portion of the upper surface of the main         body.

In the semiconductor module,

-   -   wherein an end of the locking portion has a rectangular shape or         a curved shape.

In the semiconductor module,

-   -   wherein the locking portion is formed by pressing upward the end         portion of the projection.

In the semiconductor module,

-   -   wherein the sealing resin has a linear expansion coefficient         that is smaller than the linear expansion coefficient of the die         pad frame, and greater than the linear expansion coefficient of         the semiconductor chip.

In the semiconductor module,

-   -   wherein the locking portion is formed by pressing upward the end         portion of the projection several times.

In the semiconductor module,

-   -   wherein a third electrode that has a smaller upper surface area         than the first electrode is disposed on the upper surface of the         semiconductor chip.

In the semiconductor module, further comprising:

-   -   a second clip frame that is disposed on the upper surface of the         semiconductor chip to be adjacent to the first clip frame, the         second clip frame having a smaller upper surface area than the         first clip frame; and     -   a second clip conductive connection member electrically         connecting the third electrode of the semiconductor chip and a         lower surface of the second clip frame.

In the semiconductor module,

-   -   wherein the first clip conductive connection member, the second         clip conductive connection member, and the conductive connection         member for die pad are soldering material members.

In the semiconductor module,

-   -   wherein the semiconductor chip is an MOS transistor,     -   wherein the first electrode is a source electrode of the MOS         transistor,     -   wherein the second electrode is a drain electrode of the MOS         transistor, and     -   wherein the third electrode is a gate electrode of the MOS         transistor.

In the semiconductor module,

-   -   wherein the protrusion of the die pad frame has one or more         laser grooves on the upper surface, the one or more grooves         being formed by laser irradiation so as to extend along the end         portion of the main body of the die pad frame.

In the semiconductor module,

-   -   wherein the one or more laser grooves on the upper surface of         the protrusion have a cross section taken along a direction         perpendicular to a length direction along which the one or more         laser grooves extend, the cross section having a V shape or a U         shape, and     -   wherein a bottom of a first laser groove among the one or more         laser grooves is positioned to be closer to a chip region where         the semiconductor chip is disposed than a center of a width of         the first laser groove.

In the semiconductor module,

-   -   wherein a direction of the laser irradiation relative to a         groove region of the upper surface of the protrusion where the         first laser groove is formed is slanted from a perpendicular         line passing through the groove region of the upper surface of         the projection toward the locking portion.

In the semiconductor module,

-   -   wherein the one or more laser grooves on the upper surface of         the protrusion have a cross section taken along a direction         perpendicular to a length direction in which the one or more the         laser grooves extend, the cross section having a V shape or a U         shape, and     -   wherein a bottom of a second laser groove among the one or more         laser groove is positioned to be closer to the locking portion         than a center of a width of the second laser groove.

In the semiconductor module,

-   -   wherein a direction of the laser irradiation relative to the         groove region of the upper surface of the protrusion where the         second laser groove is formed is slanted from a perpendicular         line passing through the groove region of the upper surface of         the protrusion toward the chip region where the semiconductor         chip is disposed.

In the semiconductor module,

-   -   wherein the laser irradiation roughens inner surfaces and edge         portions of the one or more laser grooves to prevent the         conductive connection member for die pad on the upper surface of         the die pad frame from spreading by getting wet.

In the semiconductor module,

-   -   wherein the die pad frame has a first side, a second side, one         end of which intersects one end of the first side, a third side,         one end of which intersects another end of the first side, and a         fourth side, one end of which intersects another side of the         second side and another side of which intersects another end of         the third side the third side,     -   wherein the protrusion and the locking portion are formed in a         region along the first side, the second side, and the third         side, and not formed in a region along the fourth side,     -   wherein the region along the fourth side of the upper surface of         the die pad frame has a through-hole passing through the main         body and improving adhesion with the sealing resin,     -   wherein the one or more laser grooves are formed by the laser         irradiation on the upper surface of the protrusion along the         first side, the second side, and the third side of the die pad         frame, and     -   wherein one or more additional laser grooves are formed by laser         irradiation along the fourth side between the region where the         through-hole is formed and the chip region.

In the semiconductor module,

-   -   wherein the one or more laser grooves are sequentially disposed         along the first side, the second side, and the third side of the         die pad frame, and     -   wherein the number of additional laser grooves is greater than         the number of lines formed by the one or more laser grooves.

In the semiconductor module,

-   -   wherein the one or more laser grooves are in communication with         the one or more additional laser groove to surround a perimeter         of the chip region of the die pad frame where the semiconductor         chip is disposed.

In the semiconductor module,

-   -   wherein a conductive metal material of the die pad frame is a         copper-based alloy or a copper-based alloy to which a different         metal selected from Sn, Zn, Fe, Cr, and Ni is added, and wherein         a surface of the die pad frame are not plated.

In the semiconductor module,

-   -   wherein a difference in height between the lower surface of the         locking portion and the lower surface of the protrusion is         greater than a difference in height between the upper surface of         the locking portion and the upper surface of the protrusion.

In the semiconductor module, wherein the lower surface of the locking portion slopes upward to an end portion of the locking portion.

In the semiconductor module,

-   -   wherein a clip locking part is disposed at an end portion of an         upper surface of the first clip frame, the clip locking part         being partially above the upper surface of the first clip frame         so as to be away from the upper surface of the semiconductor         chip; and     -   wherein a lower surface of the clip locking part slopes upward         to an end of the clip locking part.

In the semiconductor module,

-   -   wherein an upper surface of the clip locking part slopes         downward to the end of the clip locking part.

In the semiconductor module,

-   -   wherein an end portion of a lower surface of the protrusion         connecting to a lower surface of the locking portion has a         curved shape.

In the semiconductor module,

-   -   wherein an end portion of a lower surface of the locking portion         has a curved shape.

Effects of the Invention

A semiconductor module in an aspect of the present invention includes:

-   -   a die pad frame;     -   a semiconductor chip disposed in a chip region on an upper         surface of the die pad frame, the semiconductor chip having an         upper surface on which a first electrode is disposed and a lower         surface on which a second electrode is disposed;     -   a conductive connection member for die pad disposed between the         second electrode of the semiconductor chip and an upper surface         of the die pad frame, the conductive connection member for die         pad electrically connecting the second electrode of the         semiconductor chip and the upper surface of the die pad frame;         and     -   a sealing resin for sealing the semiconductor chip, the die pad         frame, and the conductive connection member for die pad.

The die pad frame has a projection disposed on an upper surface at an end of the die pad frame and protruding from the upper surface of the die pad frame in a direction that is parallel to the upper surface of the die pad frame, the projection being intended to improve the adhesion with the sealing resin. The projection has, at its end, a locking portion that is partially located above the upper surface of the projection.

The locking portion at the end of the projection of the die pad frame may block the conductive connection member for die pad.

Furthermore, in a region near the end of the projection of the die pad frame, the locking portion may prevent the sealing resin from shrinking and in turn prevent the sealing resin from cracking or separating.

Thus, the semiconductor module according to the present invention may prevent the flow of the conductive connection member that electrically connects the semiconductor chip and the die pad frame in a region at an end of the die pad frame, while preventing the occurrence of a crack or separation of the sealing resin at an end portion of the die pad frame.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top view illustrating an example of an external appearance of a semiconductor module 100 according to a first embodiment.

FIG. 2 is a bottom view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1.

FIG. 3 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1 viewed from a direction that is opposite to a first direction D1.

FIG. 4 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1, viewed from a second direction D2.

FIG. 5 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1 viewed from the first direction D1.

FIG. 6 is a top view illustrating an example of an internal appearance of the semiconductor module 100 shown in FIG. 1.

FIG. 7 is a cross-sectional view illustrating an example of a cross section of the semiconductor module shown in FIG. 6 taken along line N-N.

FIG. 8 is a cross-sectional view illustrating another example of the cross section of the semiconductor module shown in FIG. 6 taken along line N-N.

FIG. 9 is a cross-sectional view illustrating an example of a cross section of a semiconductor module according to a second embodiment.

FIG. 10 is a cross-sectional view illustrating another example of the cross section of the semiconductor module according to the second embodiment.

FIG. 11 is a top view illustrating an example of a configuration on an upper surface of a die pad frame DF included in the semiconductor module according to the second embodiment.

FIG. 12 is a cross-sectional view of the die pad frame DF, illustrating an example of a process of forming a laser groove LM on the upper surface of the projection T of the die pad frame DF by laser irradiation.

FIG. 13 is a cross-sectional view of the die pad frame DF, illustrating an example of a process of forming first and second laser grooves LMa and LMb on the upper surface of the projection T of the die pad frame DF by laser irradiation.

FIG. 14 is a top view illustrating an example of an appearance of the conventional semiconductor module.

FIG. 15 is a cross-sectional view illustrating an example of a cross section of the conventional semiconductor module shown in FIG. 14 taken along line N-N.

EMBODIMENTS FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will now be described with reference the accompanying drawings.

First Embodiment

FIG. 1 shows a top view illustrating an example of an external appearance of a semiconductor module 100 according to a first embodiment. FIG. 2 is a bottom view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1. FIG. 3 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1 viewed from a direction that is opposite to a first direction D1. FIG. 4 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1, viewed from a second direction D2. FIG. 5 is a side view of the example of the external appearance of the semiconductor module 100 shown in FIG. 1 viewed from the first direction D1. FIG. 6 is a top view illustrating an example of an internal appearance of the semiconductor module 100 shown in FIG. 1. FIG. 7 is a cross-sectional view illustrating an example of a cross section of the semiconductor module shown in FIG. 6 taken along line N-N. FIG. 8 is a cross-sectional view illustrating another example of the cross section of the semiconductor module shown in FIG. 6 taken along line N-N. In FIG. 6, the sealing member A is illustrated as a transparent member.

As shown in FIGS. 1 to 8, for example, the semiconductor module 100 according to the first embodiment includes a die pad frame (lead frame) DF, a semiconductor chip CX, a conductive connection member for die pad A2, a sealing resin H, a first clip frame CF1, a first clip conductive connection member A1, a second clip frame CF2, and a second clip conductive connection member A3.

In this embodiment, the semiconductor module 100 functions as a three-terminal semiconductor device (MOS transistor).

The semiconductor chip CX is disposed in a chip region CXa on an upper surface of the die pad frame DF.

A first electrode (source electrode) S is disposed on an upper surface, and a second electrode (drain electrode) D is disposed on a lower surface of the semiconductor chip CX. A third electrode (gate electrode) G that has a smaller upper surface area than the first electrode S is also disposed on the upper surface of the semiconductor chip CX.

In this embodiment, the semiconductor chip CX is a MOS transistor, for example. In this case, the first electrode S is a source electrode of the MOS transistor, the second electrode D is a drain electrode of the MOS transistor, and the third electrode G is a gate electrode of the MOS transistor.

The conductive connection member for die pad A2 is disposed between the second electrode D of the semiconductor chip CX and the upper surface of the die pad frame DF.

The conductive connection member for die pad A2 electrically connects the second electrode D of the semiconductor chip CX and the upper surface of the die pad frame DF.

The conductive connection member for die pad A2 is, for example, a soldering material member.

As shown in FIGS. 6 and 7, for example, the first clip frame CF1 is disposed on the upper surface of the semiconductor chip CX.

The first clip frame CF1 has terminals CF1 a, CF1 b, and CF1 c protruding from the sealing resin H, as shown in FIGS. 1 to 6, for example.

The first clip frame CF1 has an upper surface CF1E, at an end of which a clip locking part DY is disposed. A part of the clip locking part DY protrudes from the upper surface of the semiconductor chip CX so as to be above the upper surface CF1E of the first clip frame CF1. An end Da of the clip locking part DY may have a rectangular shape or a curved shape.

The clip locking part DY performs a mold lock of the sealing resin H near an end portion of the first clip frame CF1.

The first clip frame CF1 has four projecting portions (dowel portions) CF1D formed by pressing the first clip frame CF1 from above, as shown in FIG. 6, for example. The four projecting portions CF1D are in contact with the first electrode (source electrode) S on the upper surface of the semiconductor chip CX directly or via the first clip conductive connection member A1.

The first clip conductive connection member A1 is disposed between the first electrode S of the semiconductor chip CX and the lower surface of the first clip frame CF1, as shown in, for example, FIGS. 7 and 8.

The first clip conductive connection member A1 electrically connects the first electrode S of the semiconductor chip CX and the lower surface of the first clip frame CF1.

The first clip conductive connection member A1 is a soldering material member, for example.

The second clip frame CF2 is disposed on the upper surface of the semiconductor chip CX to be adjacent to the first clip frame CF1.

The second clip frame CF2 has a terminal CF2 a protruding from the sealing resin H.

The second clip frame CF2 has a smaller upper surface area than the first clip frame CF1.

The second clip conductive connection member A3 electrically connects the third electrode G of the semiconductor chip CX and the lower surface of the second clip frame CF2.

The second dip conductive connection member A3 is a soldering material member, for example.

The sealing resin H seals the semiconductor chip CX, the die pad frame DF, the first clip frame CF1, the first clip conductive connection member A1, the second clip frame CF2, the second clip conductive connection member A3, and the conductive connection member for die pad A2.

The linear expansion coefficient of the sealing resin H is set to be smaller than that of the die pad frame DF, and greater than that of the semiconductor chip CX, for example.

The die pad frame (lead frame) DF has a first side DF1, a second side DF2, one end of which intersects one end of the first side DF1, a third side DF3, one end of which intersects the other end of the first side DF1, and a fourth side DF, one end of which intersects the other end of the second side DF2 and the other end of which intersects the other end of the third side DF3.

Thus, the die pad frame DF has a substantially rectangular shape.

The die pad frame DF has a projection T intended to improve the adhesion with the sealing resin H.

The projection T is disposed on an upper side of an end Ba of a main body B of the die pad frame DF and protrudes from the upper surface of the main body B of the die pad frame DF in a direction that is parallel to the upper surface of the main body B of the die pad frame DF (for example, a second direction D2), as shown in FIGS. 6 and 7.

With this structure, the projection T may improve the adhesion between the die pad frame DF and the sealing resin H.

The projection T has, at its end, a locking portion U that is partially located above the upper surface of the projection T.

The locking portion U has a step portion Ub that protrudes upward from an upper surface of an end Ta of the projection T, as shown in FIG. 7, for example. The locking portion U may also have a step portion Uc on its lower surface by which the edge portion is raised.

The sealing resin H near the upper surface of the end portion of the projection T may be locked in this manner to complete the mold lock.

The step portion Ub of the locking portion U is formed by pressing upward the end portion of the projection T, for example.

The locking portion U may have two or more step portions Ub that protrude from the upper surface of the end portion Ta of the projection T sequentially (in a stepwise manner). Furthermore, the locking portion U may have two or more step portions Uc that are provided on the lower surface in a stepwise manner.

This allows the sealing resin H around the upper surface of the end portion of the projection T to be locked by the two or more step portions Ub protruding upward from the upper surface of the end portion of the projection T in a stepwise manner to surely complete the mold lock.

The step portions Ub of the locking portion U are formed by pressing the end portion of the projection T several times, for example.

The height of the top part of the locking portion U may be higher than the height of the top part of the conductive connection member for die pad A2 so as to block the flow of the conductive connection member for die pad A2, as shown in FIGS. 7 and 8, for example.

The length of the locking portion U in the direction along which the projection T extends (for example, the second direction D2) is set to be shorter than the length of the projection T excluding the locking portion U, as shown in FIGS. 7 and 8, for example. If necessary, the length of the locking portion U may be longer than the length of the projection T excluding the locking portion U.

An end Ua of the locking portion U has a rectangular shape or a curved shape.

The die pad frame DF is formed of a conductive metal material, which is a copper (Cu)-based alloy or a copper (Cu)-based alloy to which a different metal such as Sn, Zn, Fe, Cr, or Ni is added. Although the surface of the die pad frame DF is not plated, it may be plated if necessary.

This enables the die pad frame DF to be formed easily.

The projection T continuously surrounds the perimeter of the end Ba of the upper surface of the main body B of the die pad frame DF (along the first, second, and third sides DF1, DF2, and DF3) as shown in FIG. 6, for example.

As shown in FIG. 6, the projection T and the locking portion U are disposed in a region along the first, second, and third sides DF1, DF2, and DF3, but not disposed in a region along the fourth side DF4.

Furthermore, as shown in FIG. 6, through-holes Z are disposed in the region of the upper surface of the die pad frame DF along the fourth side DF4, the through-hole Z penetrating the main body B and being intended to improve the adhesion of the die pad frame DF with the sealing resin H.

In the through-hole Z, the thickness of the die pad frame DF on the side sealed by the sealing resin H is the same as the thickness of the projection T (that is a half of the thickness of the central portion of the die pad frame DF). This improves the adhesion of the die pad frame DF and the sealing resin H.

The locking portion U may have the same thickness as the projection T, for example.

The height Uch of the step portion Uc between the lower surface U1 of the locking portion U and the lower surface T1 of the projection T may be greater than the height Ubh of the step portion Ub between the upper surface U2 of the locking portion U and the upper surface T2 of the projection T (FIG. 7).

The lower surface U1 of the locking portion U may slope upward to the end of the locking portion U (the region UR in FIG. 7). This may reduce the stress of the sealing resin H.

The clip locking part DY disposed at the end portion of the upper surface CF1E of the first clip frame CF1 is partially above the upper surface CF1E of the first clip frame CF1 to be away from the upper surface of the semiconductor chip CX. The lower surface DY1 of the clip locking part DY may slope upward to the end of the clip locking part DY (the region DYR1 in FIG. 7). This may improve the insulation between the clip locking part DY and the lower surface DY1 of the semiconductor chip CX further.

The upper surface DY2 of the clip locking part DY may slope downward to the end of the clip locking part DY (the region DYR2 in FIG. 7). This may reduce the stress of the sealing resin H at the end portion of the clip locking part DY and improve the adhesion between the end portion of the clip locking part DY and the sealing resin H.

An end Tb of the lower surface of the projection T connecting to the lower surface U1 of the locking portion U (FIG. 7) may have a curved shape instead of a rectangular shape. This may reduce the stress of the sealing resin H at the end portion Tb of the projection T.

An end Ud of the lower surface U1 of the locking portion U (FIG. 7) may have a curved shape instead of a rectangular shape. This may reduce the stress of the sealing resin H at the end Ud of the locking portion U.

As described above, in the semiconductor module 100 having the above-described structure, the locking portion U at the end of the projection T of the die pad frame may block the conductive connection member for die pad.

The locking portion U may prevent the sealing resin from shrinking in a region near the end of the projection T of the die pad frame, and in turn prevent the sealing resin from cracking or separating.

Thus, the semiconductor module according to the first embodiment is capable of preventing the flow of the conductive connection member that electrically connects the semiconductor chip and the die pad frame in a region at the end of the die pad frame, while preventing the occurrence of a crack or separation of the sealing resin at an end portion of the die pad frame.

Second Embodiment

A second embodiment having a structure in which a laser groove is provided to the upper surface of the projection T of the die pad frame DF included in the semiconductor module will be described below.

FIG. 9 is a cross-sectional view illustrating an example of a cross section of a semiconductor module according to a second embodiment. FIG. 10 is a cross-sectional view illustrating another example of the cross section of the semiconductor module according to the second embodiment. FIG. 11 is a top view illustrating an example of a configuration on an upper surface of a die pad frame DF included in the semiconductor module according to the second embodiment. FIG. 12 is a cross-sectional view of the die pad frame DF, illustrating an example of a process of forming a laser groove LM on the upper surface of the projection T of the die pad frame DF by laser irradiation. FIG. 13 is a cross-sectional view of the die pad frame DF, illustrating an example of a process of forming first and second laser grooves LMa and LMb on the upper surface of the projection T of the die pad frame DF by laser irradiation.

The cross sections of the semiconductor module shown in FIGS. 9 and 10 are obtained by providing additional grooves to the cross section of the first embodiment taken along line N-N of FIG. 6. The die pad frame DF of the semiconductor module according to the second embodiment shown in FIG. 11 may be applied to the semiconductor module 100 according to the first embodiment shown in FIGS. 1 to 6.

As shown in FIGS. 9 to 11 for example, one or more laser grooves LM (LM1, LM2, LM3) are formed by laser irradiation on the upper surface of the projection T of the die pad frame DF along the end Ba of the main body B of the die pad frame DF.

The cross section of the laser grooves LM in a direction perpendicular to the direction along which the laser grooves LM extend on the upper surface of the projection T (for example, the first direction D1 shown in FIGS. 9 and 10) has a V shape.

However, the cross section of the laser grooves LM in a direction perpendicular to the direction along which the laser grooves LM extend on the upper surface of the projection T (for example, the first direction D1 shown in FIGS. 9 and 10) may have a U shape.

The die pad frame DF has a first side DF1, a second side DF2, one end of which intersects one end of the first side DF1, a third side DF3, one end of which intersects the other end of the first side DF1, and a fourth side DF, one end of which intersects the other end of the second side DF2 and the other end of which intersects the other end of the third side DF3, as shown in FIG. 11, for example.

The die pad frame DF thus has a substantially rectangular shape as in the first embodiment.

The projection T and the locking portion U are disposed in a region along the first, second, and third sides DF1, DF2, and DF3, but not disposed in a region along the fourth side DF4, as shown in FIG. 11.

A through-hole Z is disposed in the region of the upper surface of the die pad frame DF along the fourth side DF4 as shown in FIG. 11, the through-hole Z penetrating the main body B and being intended to improve the adhesion of the die pad frame DF with the sealing resin H.

In the second embodiment, the laser grooves LM (LM1, LM2, LM3) are formed by laser irradiation on the upper surface of the projection T along the first, second, and the third side DF1, DF2, DF3 of the die pad frame DF, as shown in FIG. 11.

Also in the second embodiment, additional laser grooves LM4 a, LM4 b, LM4 c, and LM4 d are formed by laser irradiation along the fourth side DF4 between the region where the through-hole Z is formed and the chip region CX, as shown in FIG. 11.

Although the example shown in FIG. 11 includes four additional laser grooves, the number of additional laser grooves may be one to three, or five or more.

The laser grooves LM1, LM2, LM3 are sequentially disposed along the first, second, and third sides DF1, DF2, and DF3 of the die pad frame DF as shown in FIG. 11, for example.

The number of additional laser grooves LM4 a, LM4 b, LM4 c, and LM4 d (four in FIG. 11) is set to be larger than the number of lines formed by sequentially disposed laser grooves LM1, LM2, and LM3 (one in FIG. 11).

As shown in FIG. 11, for example, the line formed by the sequentially disposed laser grooves LM1, LM2, and LM3 is connected to the additional laser groove LM4 a so as to surround the perimeter of the chip region CXa of the die pad frame DF where the semiconductor chip CX id disposed.

As in the first embodiment, the conductive metal material of the die pad frame DF is a copper (Cu)-based alloy or a copper (Cu)-based alloy to which a different metal such as Sn, Zn, Fe, Cr, or Ni is added. Although the surface of the die pad frame DF is not plated, it may be plated if necessary.

This enables the die pad frame DF to be formed easily.

As shown in FIG. 12, for example, when the laser grooves LM are formed, the direction of laser irradiation DL relative to a groove region DX on the upper surface of the projection T where the laser grooves LM are formed is set to be parallel to a perpendicular line P passing through the groove region DX on the upper surface of the projection T.

As a result, the cross section of the laser grooves LM substantially have a V shape in which the bottom is located on the center of the width of the laser groove LM (for example, the width in the second direction D2).

The laser irradiation roughens the inner surfaces and the edge portions of the laser grooves LM. The roughness prevents the conductive connection member for die pad A2 from spreading by getting wet on the upper surface of the die pad frame DF.

As shown in FIG. 13, for example, the bottom LMas of a first laser groove LMa among the laser grooves LM may be located to be closer to the chip region CXa where the semiconductor chip CX is disposed than the center LMam in the width of the first laser groove LMa (for example, the width in the second direction D2).

The mold lock of the sealing resin H may be performed more reliably in this manner.

The direction DLa of the laser irradiation relative to the groove region DX on the upper surface of the projection T to form the first laser groove LMa in the above-described manner is slanted from the perpendicular line P that passes through the groove region DX on the upper surface of the projection T toward the locking portion U, as shown in FIG. 13, for example.

This allows the first laser groove LMa to be formed so that the bottom LMas is closer to the chip region CXa than the center LMam in the width of the first laser groove LMa (for example, the width in the second direction D2).

Furthermore, as shown in FIG. 13, for example, the bottom LMbs of a second laser groove LMb among the laser grooves LM may be located to be closer to the locking portion U than to the center LMbm of the width of the second laser groove LMb (for example, the width in the second direction D2).

This may block the flow of the conductive connection member for die pad A2 more reliably, for example.

The direction DLb of the laser irradiation relative to the groove region DX on the upper surface of the projection T to form the second laser groove LMb in the above-described manner is slated from the perpendicular line P that passes through the groove region DX on the upper surface of the projection T toward the chip region CXa where the semiconductor chip CX is disposed, as shown in FIG. 13, for example.

This allows the second laser groove LMb to be formed so that the bottom LMbs is closer to the locking portion U than the center LMbm in the width of the second laser groove LMb (for example, the width in the second direction D2).

The other members of the semiconductor module according to the second embodiment are the same as those of the first embodiment.

Thus, the semiconductor module according to the second embodiment is capable of preventing the flow of a conductive connection member that electrically connects the semiconductor chip and the die pad frame in a region at the end of the die pad frame, while preventing the occurrence of a crack or separation of the sealing resin at an end portion of the die pad frame.

Third Embodiment

In the first embodiment, the semiconductor chip CX is an MOSFET. However, other semiconductor elements may also be used.

Specifically, the semiconductor chip CX may be a diode, an insulated gate bipolar transistor (IGBT), or other FETs.

The other elements of the semiconductor module according to the third embodiment are the same as those of the first embodiment or the second embodiment.

Thus, the semiconductor module according to the third embodiment is capable of preventing the flow of the conductive connection member that electrically connects the semiconductor chip and the die pad frame in a region at the end of the die pad frame, while preventing the occurrence of a crack or separation of the sealing resin at the end portion of the die pad frame.

As described above, a semiconductor module in an aspect of the present invention includes:

-   -   a die pad frame DF;     -   a semiconductor chip CX disposed in a chip region CXa on an         upper surface of the die pad frame, the semiconductor chip         having an upper surface on which a first electrode (source         electrode) is disposed and a lower surface on which a second         electrode (drain electrode) is disposed;     -   a conductive connection member for die pad A2 disposed between         the second electrode of the semiconductor chip and an upper         surface of the die pad frame, the conductive connection member         for die pad electrically connecting the second electrode of the         semiconductor chip and the upper surface of the die pad frame;         and     -   a sealing resin H for sealing the semiconductor chip, the die         pad frame, and the conductive connection member for die pad.

The die pad frame DF has a projection T disposed on an upper surface at an end of the die pad frame and protruding from the upper surface of the die pad frame in a direction that is parallel to the upper surface of the die pad frame, the projection T being intended to improve the adhesion with the sealing resin H. The projection T has, at its end, a locking portion U that is partially located above the upper surface of the projection T.

The locking portion U at the end of the projection T of the die pad frame may block the conductive connection member for die pad. Furthermore, in a region near the end of the projection T of the die pad frame, the locking portion U may prevent the sealing resin from shrinking and in turn prevent the sealing resin from cracking or separating.

Thus, the semiconductor module according to the present invention may prevent the flow of the conductive connection member that electrically connects the semiconductor chip and the die pad frame in a region at an end of the die pad frame, while preventing the occurrence of a crack or separation of the sealing resin at an end portion of the die pad frame.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. The embodiments may be embodied in a variety of other forms.

Furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The embodiments and their modifications are included in the scope and the subject matter of the invention, and at the same time included in the scope of the claimed inventions and their equivalents.

EXPLANATION OF REFERENCES

100: semiconductor module

DF: die pad frame (lead frame)

CX: semiconductor chip

A2: conductive connection member for die pad

H: sealing resin

CF1: first clip frame

A1: first clip conductive connection member

CF2: second clip frame

A3: second clip conductive connection member

DF1: first side

DF2: second side

DF3: third side

DF4: fourth side

T: protrusion

B: main body

LM: laser groove

LM1, LM2, LM3: laser groove

LM4 a, LM4 b, LM4 c, LM4 d: additional laser groove 

The invention claimed is:
 1. A semiconductor module comprising: a die pad frame; a semiconductor chip disposed in a chip region on an upper surface of the die pad frame, the semiconductor chip having an upper surface on which a first electrode is disposed and a lower surface on which a second electrode is disposed; a conductive connection member for die pad disposed between the second electrode of the semiconductor chip and the upper surface of the die pad frame, the conductive connection member for die pad electrically connecting the second electrode of the semiconductor chip and the upper surface of the die pad frame; and a sealing resin for sealing the semiconductor chip, the die pad frame, and the conductive connection member for die pad, wherein the die pad frame has a projection disposed on the upper surface at an end portion of the die pad frame and protruding from an upper surface of a main body of the die pad frame in a direction that is parallel to the upper surface of the main body of the die pad frame, the projection being intended to improve the adhesion with the sealing resin, wherein the projection has, at its end, a locking portion that is partially located above an upper surface of the projection, and wherein the projection of the die pad frame has one or more laser grooves on the upper surface, the one or more grooves being formed by laser irradiation so as to extend along the end portion of the main body of the die pad frame.
 2. The semiconductor module according to claim 1, wherein the one or more laser grooves on the upper surface of the projection have a cross section taken along a direction perpendicular to a length direction along which the one or more laser grooves extend, the cross section having a V shape or a U shape, and wherein a bottom of a first laser groove among the one or more laser grooves is positioned to be closer to a chip region where the semiconductor chip is disposed than a center of a width of the first laser groove.
 3. The semiconductor module according to claim 2, wherein a direction of the laser irradiation relative to a groove region of the upper surface of the projection where the first laser groove is formed is slanted from a perpendicular line passing through the groove region of the upper surface of the projection toward the locking portion.
 4. The semiconductor module according to claim 1, wherein the one or more laser grooves on the upper surface of the projection have a cross section taken along a direction perpendicular to a length direction in which the one or more the laser grooves extend, the cross section having a V shape or a U shape, and wherein a bottom of a second laser groove among the one or more laser groove is positioned to be closer to the locking portion than a center of a width of the second laser groove.
 5. The semiconductor module according to claim 4, wherein a direction of the laser irradiation relative to a groove region of the upper surface of the projection where the second laser groove is formed is slanted from a perpendicular line passing through the groove region of the upper surface of the projection toward the chip region where the semiconductor chip is disposed.
 6. The semiconductor module according to claim 1, wherein the laser irradiation roughens inner surfaces and edge portions of the one or more laser grooves to prevent the conductive connection member for die pad on the upper surface of the die pad frame from spreading by getting wet.
 7. The semiconductor module according to claim 1, wherein the die pad frame has a first side, a second side, one end of which intersects one end of the first side, a third side, one end of which intersects another end of the first side, and a fourth side, one end of which intersects another side of the second side and another side of which intersects another end of the third side, wherein the projection and the locking portion are formed in a region along the first side, the second side, and the third side, and not formed in a region along the fourth side, wherein the region along the fourth side of the upper surface of the die pad frame has a through-hole passing through the main body and improving adhesion with the sealing resin, wherein the one or more laser grooves are formed by the laser irradiation on the upper surface of the projection along the first side, the second side, and the third side of the die pad frame, and wherein one or more additional laser grooves are formed by laser irradiation along the fourth side between the region where the through-hole is formed and the chip region.
 8. The semiconductor module according to claim 7, wherein the one or more laser grooves are sequentially disposed along the first side, the second side, and the third side of the die pad frame, and wherein the number of additional laser grooves is greater than the number of lines formed by the one or more laser grooves.
 9. The semiconductor module according to claim 7, wherein the one or more laser grooves are in communication with the one or more additional laser groove to surround a perimeter of the chip region of the die pad frame where the semiconductor chip is disposed.
 10. The semiconductor module according to claim 1, wherein a conductive metal material of the die pad frame is a copper-based alloy or a copper-based alloy to which a different metal selected from Sn, Zn, Fe, Cr, and Ni is added, and wherein a surface of the die pad frame are not plated. 